Understanding the Laser Powder Bed Fusion of AlSi10Mg Alloy

Holden Hyer; Le Zhou; Sharon Park; Guilherme Gottsfritz; George Benson; Bjorn Tolentino; Brandon McWilliams; Kyu Cho; Yongho Sohn

doi:10.1007/s13632-020-00659-w

Understanding the Laser Powder Bed Fusion of AlSi10Mg Alloy

Holden Hyer, Le Zhou, Sharon Park, Guilherme Gottsfritz, George Benson, Bjorn Tolentino, Brandon McWilliams, Kyu Cho, Yongho Sohn

Research output: Contribution to journal › Article › peer-review

80 Scopus citations

Abstract

We examine the microstructural characteristics of LPBF AlSi10Mg produced by using a wide range of LPBF processing parameters with independently varied laser power, hatch spacing, scan speed, slice thickness, and the normalized energy density. The lower energy density produced lack of fusion flaws from residual interparticle spacing, while the higher energy density produced spherical pores from trapped gas. The highest density (> 99%) samples were produced by using an energy density of 32 to 54 J/mm³. Within this energy density range, use of smaller slice thicknesses increased the processing window that would produce dense AlSi10Mg samples. A cellular structure, consisting of Al–Si eutectic and α-Al (fcc) matrix, within melt pools was quantified in size to determine the cooling rate of 10⁵ to 10⁷ K/s. This sub-grain cellular structure was found to decrease in size with increasing scan speed and increasing slice thickness.

Original language	English
Pages (from-to)	484-502
Number of pages	19
Journal	Metallography, Microstructure, and Analysis
Volume	9
Issue number	4
DOIs	https://doi.org/10.1007/s13632-020-00659-w
State	Published - Aug 1 2020
Externally published	Yes

Funding

This research was sponsored, in part by the Office of Naval Research (No. N00014-17-1-2559) and in part by the CDCC Army Research Laboratory (No. W911NF1720172). The views, opinions, and conclusions made in this document are those of the authors and should not be interpreted as representing the official policies, either expressed or implied, of the Office of Naval Research or the US Army Research Laboratory or the US Government. The US Government is authorized to reproduce and distribute reprints for Government purposes notwithstanding any copyright notation herein. This research was sponsored, in part by the Office of Naval Research (No. N00014-17-1-2559) and in part by the CDCC Army Research Laboratory (No. W911NF1720172). The views, opinions, and conclusions made in this document are those of the authors and should not be interpreted as representing the official policies, either expressed or implied, of the Office of Naval Research or the US Army Research Laboratory or the US Government. The US Government is authorized to reproduce and distribute reprints for Government purposes notwithstanding any copyright notation herein.

Funders	Funder number
CDCC Army Research Laboratory
US Government
Office of Naval Research	N00014-17-1-2559
Army Research Laboratory	W911NF1720172

Keywords

Additive Manufacturing
Aluminum Alloys
Microstructure
Solidification

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

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10.1007/s13632-020-00659-w

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abstract = "We examine the microstructural characteristics of LPBF AlSi10Mg produced by using a wide range of LPBF processing parameters with independently varied laser power, hatch spacing, scan speed, slice thickness, and the normalized energy density. The lower energy density produced lack of fusion flaws from residual interparticle spacing, while the higher energy density produced spherical pores from trapped gas. The highest density (> 99%) samples were produced by using an energy density of 32 to 54 J/mm3. Within this energy density range, use of smaller slice thicknesses increased the processing window that would produce dense AlSi10Mg samples. A cellular structure, consisting of Al–Si eutectic and α-Al (fcc) matrix, within melt pools was quantified in size to determine the cooling rate of 105 to 107 K/s. This sub-grain cellular structure was found to decrease in size with increasing scan speed and increasing slice thickness.",

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AU - Zhou, Le

AU - Park, Sharon

AU - Gottsfritz, Guilherme

AU - Benson, George

AU - Tolentino, Bjorn

AU - McWilliams, Brandon

AU - Cho, Kyu

AU - Sohn, Yongho

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AB - We examine the microstructural characteristics of LPBF AlSi10Mg produced by using a wide range of LPBF processing parameters with independently varied laser power, hatch spacing, scan speed, slice thickness, and the normalized energy density. The lower energy density produced lack of fusion flaws from residual interparticle spacing, while the higher energy density produced spherical pores from trapped gas. The highest density (> 99%) samples were produced by using an energy density of 32 to 54 J/mm3. Within this energy density range, use of smaller slice thicknesses increased the processing window that would produce dense AlSi10Mg samples. A cellular structure, consisting of Al–Si eutectic and α-Al (fcc) matrix, within melt pools was quantified in size to determine the cooling rate of 105 to 107 K/s. This sub-grain cellular structure was found to decrease in size with increasing scan speed and increasing slice thickness.

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Understanding the Laser Powder Bed Fusion of AlSi10Mg Alloy

Abstract

Funding

Keywords

UN SDGs

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